Collapsible crate

ABSTRACT

A collapsible crate includes a structural base and at least one collapsible corner post assembly coupled to the base. The corner post assembly includes supports configured to provide lateral protection to a payload in the crate. The corner post assembly is moveable between an upright position and a collapsed position. The crate can further be stackable and/or returnable.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims the benefit of U.S. Provisional PatentApplication No. 62/344,748, filed Jun. 2, 2016, which is incorporatedherein by reference in its entirety.

BACKGROUND

Various different styles of crates are available for industrialpackaging. In certain applications, these crates must be strong enoughto support large payloads. For example, industrial packaging crates areused for the protection, shipment and/or storage of all-terrain vehicles(ATVs), snowmobiles, motorcycles, boat motors, and other heavy payloads.Often, these crates are collapsible so that they can be disassembled andreturned once empty. For ATVs and other payloads, these crates typicallyuse an all-steel construction, which is expensive. To reduce cost,others have used crates made at least partially from cardboard, butthese crates are not strong enough for stacking. Other crates have usedwood, but these are often configured to be disposed of after one use,and are not collapsible or returnable. Other wood crates are collapsibleand may be returnable/reusable, but these require additional hardware toassemble and collapse, and are typically not designed to be durableenough for more than a few uses.

BRIEF SUMMARY

According to one embodiment of the invention, a collapsible crateincludes a structural base having at least one corner, and a collapsiblecorner post assembly coupled to the base. The corner post assemblyincludes a post mount coupled to the corner and an elongated postcoupled to the post mount. The elongated post is moveable relative tothe post mount between an upright position in which the elongated postextends substantially vertically and a collapsed position in which theelongated post lies substantially horizontally.

According to another embodiment of the invention, a collapsible cornerpost assembly for a crate includes a post mount and an elongated postcoupled to the post mount. The elongated post is moveable relative tothe post mount between an upright position in which the elongated postextends upwardly from the post mount and a collapsed position in whichthe elongated post extends laterally from the post mount.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a perspective view of a crate according to a first embodimentof the invention, with the crate shown in an assembled configuration;

FIG. 2 is a side view of the crate of FIG. 1;

FIG. 3 is an end view of the crate of FIG. 1;

FIG. 4 is a perspective view of two stacked assembled crates of FIG. 1;

FIG. 5 is a side view of the stacked assembled crates of FIG. 4;

FIG. 6 is an end view of the stacked assembled crates of FIG. 4;

FIG. 7 is a perspective view of two stacked collapsed crates of FIG. 1;

FIG. 8 is a side view of the stacked collapsed crates of FIG. 7;

FIG. 9 is an end view of the stacked collapsed crates of FIG. 7;

FIG. 10 is an exploded view of a corner portion of the crate of FIG. 1;

FIG. 11 is a perspective view of a corner post assembly of the crate ofFIG. 1, where the corner post assembly is in an upright and extendedposition;

FIG. 12 is a perspective view of the corner post assembly of FIG. 11,where the corner post assembly is in an upright and retracted position;

FIG. 13 is a perspective view of the corner post assembly of FIG. 11,where the corner post assembly is in a collapsed position;

FIGS. 14-16 are views showing the movement of the corner post assemblyfrom the upright position to the collapsed position;

FIG. 17 is a perspective view of a crate according to a secondembodiment of the invention, with the crate shown in an assembledconfiguration;

FIG. 18 is a perspective view of two stacked assembled crates of FIG.17;

FIG. 19 is a perspective view of two stacked collapsed crates of FIG.17;

FIG. 20 is an exploded view of a corner portion of the crate of FIG. 17;

FIG. 21 is a close-up perspective view of the top of one of the cornerpost assembly of the crate of FIG. 17;

FIG. 22 is a close-up view of an interface between the stacked cratesshown in FIG. 18;

FIGS. 23-24 are views showing the movement of the corner post assemblyfrom the upright position to the collapsed position;

FIG. 25 is a side view of a portion of a corner post assembly for acrate according to a third embodiment of the invention, with the cornerpost assembly shown in an assembled position;

FIG. 26 is a side view of a portion of the corner post assembly fromFIG. 25, with the corner post assembly shown in a collapsed position;and

FIG. 27 is a perspective view of a portion of the corner post assemblyfrom FIG. 25, with the corner post assembly shown in a collapsedposition.

DETAILED DESCRIPTION

The invention relates to a crate for industrial packaging. In one of itsaspects, the invention relates to an improved crate that is collapsible,stackable, and, optionally, returnable. The crate can be reusable, andcan be easily and conveniently assembled or disassembled as needed.Areas in which the invention has potential application include theprotection, shipment and/or storage of goods, including a wide varietyof products. The crate may be primarily used for industrial, mid-streampayload transport, and can be used in any number of transportmodalities. One particular application in which the crate iscontemplated for use is the protection, shipment and/or storage ofall-terrain vehicles (ATVs). Other particular applications in which thecrate is contemplated for use is the protection, shipment and/or storageof snowmobiles, motorcycles, boat motors, and other heavy payloads

FIGS. 1-3 show a collapsible, stackable, and returnable crate 10according to one embodiment of the invention. There are three primarycomponent groups of the crate 10, including a structural base 12,collapsible corner post assemblies 14, and various mechanical fasteners,described in more detail below. For purposes of description related tothe figures, the terms “upper,” “lower,” “vertical,” “horizontal,” andderivatives thereof shall relate to an orientation of the crate 10 asshown in FIG. 1, with a lower side of the crate facing and resting on asurface (not shown). However, it is to be understood that the inventionmay assume various alternative orientations, except where expresslyspecified to the contrary.

The structural base 12 defines a support surface for a payload. Thestructural base 12 can be preferably fabricated from wood, while thecorner post assemblies 14 can be preferably fabricated from metal, suchas steel. This combination of materials offers a reduced-cost,collapsible crate that is robust enough to support large payloads suchas ATVs, and can further be stacked when assembled with at least oneother crate 10 as shown in FIGS. 4-6 or stacked when collapsed with atleast one other crate 10 as shown in FIGS. 7-9.

The structural base 12 may be customized based on the payload. Thestructural base 12 of the illustrated embodiment is customized for anATV, and includes a plurality of boards or slats that are mechanicallyfastened to each other to create the structural base 12. The slatsinclude a plurality of bottom deckboards 18 and a plurality of topdeckboards 20 that are mechanically fastened to a plurality of stringerboards 22 running transversely to and between the deckboards 18, 20.Blocks 24 can also be provided between and mechanically fastened to theend deckboards 18, 20, and can lie between adjacent stringer boards 22.Mechanical fasteners such as nails, screws, pins, bolts, rivets, ties,or the like can be used for the mechanical attachments of the base 12.Furthermore, other joining methods of assembling the base 12 can also beused.

Other embodiments of the structural base 12 are possible, includingdifferent configurations of the slats than that shown herein. While acustomized base 12 is shown herein, the base on which the corners posts14 are mounted can be any type of base. For example, in one embodiment,the structural base 12 can be a pallet. Furthermore, the corner postassemblies 14 are adapted to be transferred between different types ofbases, as described in further detail below. Also, while it is preferredthat the structural base 12 be manufactured from a low-cost materialsuch as wood, in other embodiments of the crate 10, the structural base12 can be manufactured using a variety of materials including wood,plastic, composite, metal, fiberglass, wood-plastic composite, or somecombination of these materials. In some applications of the crate 10, itis preferred that the structural base 12 be constructed of a materialthat is lower cost than the material used for the corner post assemblies14.

FIG. 10 is an exploded view of a corner portion of the crate 10 of FIG.1, and shows one of the corner post assemblies 14 exploded from a cornerof the structural base 12. The collapsible corner post assemblies 14 areupright supports configured to provide lateral protection to the payloadsupported by the base 12, and are adapted to allow multiple crates to bestacked when assembled or when collapsed shown in FIGS. 4-9. The cornerpost assemblies 14 can include a telescoping post 26, a post mount 28configured to couple the telescoping post 26 to the structural base 12,diagonal attachment plates 30 mountable to the structural base 12, anddiagonal braces 32 extending between the telescoping posts 26 and theattachment plates 30. While in the illustrated embodiment, the cornerpost assembly 14 is shown as having a telescoping post 26, in otherembodiments of the crate 10, the post 26 can be a single post having afixed length.

The various components of the corner post assembly 14 can be attachedusing mechanical fasteners; alternatively, some of the variouscomponents can be welded, or otherwise attached. While the corner postassemblies 14 can be preferably fabricated from metal, and moreparticularly from steel, in other embodiments, the corner postassemblies 14 can be manufactured using a variety of materials includingmetal, plastic, composite, wood, fiberglass, wood-plastic composite, orsome combination of these materials. In some applications of the crate10, it is preferred that the corner post assemblies 14 be constructed ofa material that is more robust than the material used for the structuralbase 12, so that the corner post assemblies 14 can withstand therepeating stacking and collapsing required of the collapsible,stackable, and returnable crate 10.

The telescoping post 26 can include multiple segments that can beexpanded or retracted as needed to change the length of the telescopingpost 26, and as illustrated herein includes a corner post main upright34 and a corner post insert 36 that fits into the main upright 34.Additional telescoping segments may be provided.

The main upright 34 includes an elongated tubular body 38 defining an atleast partially hollow interior and having an open upper end 40 in whichthe post insert 36 can be at least partially received and an open lowerend 42 which couples with the post mount 28. Tabs 44 extend from thelower end 42 of the tubular body 38 and include slots 46 which areelongated generally in the lengthwise direction of the main upright 34.The slotted tabs 44 can comprise a pair of plates or flat bodiesprovided on opposing sides of the tubular body 38. A series of holes 48are formed along the same opposing sides of the tubular body 38, and arespaced along the length of the tubular body 38. Each hole 48 on one sideof the tubular body 38 is aligned with a hole 48 on the opposing side,though only one holes 48 on the opposing side is visible in FIG. 10.Brace tabs 50 extend from the tubular body 38 and each has a hole 52formed near a free end of the tab 50 for coupling with the diagonalbraces 32 as described in more detail below. In the illustratedembodiment, the brace tabs 50 extend laterally from adjacent sides ofthe tubular body 38. Alternative configurations of attaching thediagonal braces 32 to the main upright 34 are possible, as long as thebraces 32 are able to collapse, as described in more detail below.

The post insert 36 includes an elongated tubular body 54 defining an atleast partially hollow interior and having an upper end 56 and a lowerend 58 which is received with the main upright 34. A series of holes 60are formed along opposing sides of the tubular body 54, though only theholes 60 on one of the opposing sides are visible in FIG. 10, and arespaced lengthwise along the tubular body 54. Each hole 60 on one side ofthe tubular body 54 is aligned with a hole 60 on the opposing side. Inthe illustrated embodiment, two holes 60 are provided, though the numbercan vary in other embodiments of the corner post assembly 14. Thespacing between the holes 60 can be in line with the spacing between theholes 48 in the main upright 34.

The post insert 36 can be slidingly received within the main upright 34and adjusted to a desired overall height of the corner post assembly 14.To fix the corner post assembly 14 at a desired height, one of the holes60 in the post insert 36 is aligned with one of the holes 48 in the mainupright 34, and a mechanical fastener is then inserted through thealigned holes 48, 60 to secure the main upright 34 and post insert 36 inplace at the desired height. The mechanical fastener illustrated hereincomprises a bolt 62 and a nut 64 which can be threaded onto the bolt 62;optionally, a washer 66 can also be provided. Other mechanical fastenersare possible, as long as the mechanical fastener can temporarily jointhe main upright 34 and post insert 36 to allow the height of the cornerpost assembly 14 to be adjusted as needed. Any fastener can be used, aslong as there is enough sheer strength in the fastener to carry the loadon the corner post assembly 14.

The upper end 56 includes a top plate 68 and a locator pin 70. The plate68 can extend outwardly from the tubular body 54 and the locator pin 70can extend upwardly from the plate 68. The locator pins 70 are adaptedto nest into the post mount 28 of another corner post assembly 14 forsecurely stacking the crates 10 (see, for example, FIGS. 4-6). Asillustrated, the locator pins 70 have a generally conical shape whichcan guide an upper crate 10 in the stack into proper alignment with alower crate 10. Alternative configurations of the locator pin 70 arepossible, as long as the crates 10 can be securely stacked, with thelocator pins 70 of the lower crate 10 in the stack securely nestedwithin a portion of the corner post assemblies 14 on the crate 10 above.

The post mount 28 includes a vertical mounting plate 72 and a horizontalmounting plate 74 coupled with a post receiver 76 configured to receivethe telescoping post 26. The mounting plates 72, 74 are configured tomount to the structural base 12, thereby mounting the telescoping post26 to the structural base 12. Specifically, the vertical mounting plate72 is coupled to the stringer board 22 and the horizontal mounting plate74 is mounted to the top deckboard 20, though in other configurations ofthe base, the plates 72, 74 may mount to other portions of the base. Themounting plates 72, 74 can be fabricated from one flat plate that isbent to define the corner between two plates 72, 74, and then welded orotherwise attached to the post receiver 76. Alternatively, the plates72, 74 can be fabricated separate flat plates that are welded orotherwise attached to form the corner.

Each plate 72, 74 includes at least one hole 78 configured to receive amechanical fastener, illustrated herein as a carriage bolt 80, used tosecure the plates to the structural base 12. Other mechanical fastenersare possible, as long as the mechanical fastener can temporarily jointhe mounting plates 72, 74 to the base 12 to allow the post mount 28 tobe removed from the structural base 12 as needed. As illustrated, thevertical mounting plate 72 includes two holes 78 that are spaced andvertically offset. Offsetting the holes 78 vertically distributes theforces from the payload over a greater area within the stringer board22. In general, the holes 78 can be aligned vertically, alignedhorizontally, and/or offset depending on the application andconstraints. Also, in the illustrated embodiment, two holes 78 areprovided, though the number can vary in other embodiments of the cornerpost assembly 14.

The post mount 28 can be configured as a universal mount, such that thecorner post assemblies 14 can be attached to any base, not just thestructural base 12 illustrated herein. The mounting plates 72, 74 can besized to accommodate attaching the post mount 28 to a base 12 havingboards or slats in a range of sizes. For example, the vertical mountingplate 72 and horizontal mounting plate 74 can be sized to accommodateattaching the post mount 28 to a 2×3 or larger stringer board 22 and a1× or larger deckboard 20, respectively. In one specific example, theplates 72, 74 can be sized to accommodate attaching the post mount 28 toa 2×3 stringer board 22 and a 2× deckboard 20. In another specificexample, the plates 72, 74 can be sized to accommodate attaching thepost mount 28 to a 2×4 stringer board 22 and a 1× deckboard 20. Theplates 72, 74 could be sized to work with smaller or larger stringerboard/deckboard combinations as well.

The post receiver 76 includes an elongated tubular body 82 defining anat least partially hollow interior and having an open upper end 84 whichengages with the main upright 34 and an open lower end 85 (FIG. 11). Alocator device, shown herein as locator tabs 86, can extend from theupper end 84 of the tubular body 82, and can extend generally in thelengthwise direction of the post receiver 76. The locator tabs 86illustrated comprise a pair of plates or flat bodies provided onopposing sides of the tubular body 82 and project from an inner surfaceof the tubular body 82. The locator tabs 86 can be welded, bolted, orotherwise formed with the post receiver 76. The locator device can takeother forms besides the tabs 86, including, but not limited to, round orsquare tubing or bar stock.

At least one pair of holes 88 is formed along the same opposing sides ofthe tubular body 82 as the locator tabs 86, though only the hole 88 onone of the opposing sides is visible in FIG. 10. In the illustratedembodiment, two spaced holes 88 are provided and are spaced lengthwisealong the tubular body 82, though the number of holes 88 can vary inother embodiments of the corner post assembly 14. Here, the upper hole88 is primarily used for the connection between the telescoping post 26and post mount 28, while the lower hole 88 is used for heavy duty loads,as described in more detail below.

In the illustrated embodiment, the bodies 38, 82 of the main upright 34and post receiver 76 can be square 2×2 tube stock and the body of thepost insert 36 can be square 1.5×1.5 tube stock that can nest within theouter tube stock forming the main upright 34. Alternatively, tube stockcan be substituted for a material that preserves the stacking andnesting functions of the corner post assembly 14. Also, while thetubular bodies are shown as having a square cross-section, othercross-sectional shapes are possible.

The main upright 34 can be slidingly received on the post receiver 76 tocouple the telescoping body 26 with the post mount 28 and alsoselectively allow the telescoping body 26 to collapse, as described infurther detail below. To fix the main upright 34 on the post receiver76, a mechanical fastener such as a bolt 90 and a nut 92 which can bethreaded onto the bolt 90 can be used; optionally, a washer 94 can alsobe provided. In the present embodiment, the bolt 90 is received by theslots 46 in the depending tabs 44 of the main upright 34 and the upperholes 88 in the post receiver 76. The bolt 90 and slotted tabs 44 form apin-in-slot joint between the telescoping post 26 and the post mount 28,which has two degrees of freedom such that the bolt 90 can slide withinthe slot 46, and the tab 44, and therefore the post 26, can rotate aboutthe bolt 90. Other joints permitting translational and rotating movementbetween the post 26 and post mount 28 can also be used. Also, while notshown, for heavy duty loads, an optional second bolt 90, along with anoptional second nut 92 and washer 94 can be provided, and can bereceived through the slots 46 and lower hole 88. However, for somepayloads, only the bolt 90 in the upper hole 88 is necessary. Othermechanical fasteners are possible, as long as the mechanical fastenercan join the main upright 34 and post receiver 76 in a manner thatallows the telescoping post 26 to collapse.

The diagonal braces 32 are configured to extend between the telescopingpost 26 and the structural base 12 to support the telescoping post 26and impart rigidity to the corner post assembly 14. As illustratedherein, the diagonal braces 32 include an elongated rigid body 96 havingopposing terminal ends 98 with holes 100 therethough. In one embodiment,the elongated body 96 can be fabricated from ½″ tube stock havingflattened ends 98 in which the holes 100 are formed. The holes 100 areconfigured to receive pins 102 that can define axes of rotation suchthat the brace 32 has the freedom to rotate about the pins 102, whichmay be useful when the corner post assembly 14 is being initiallyassembled and installed on the base 12, or when the corner post assembly14 is being collapsed. The diagonal braces 32 can extend at roughly a 45angle between the telescoping posts 26 and the attachment plates 30,although other angles are possible.

The diagonal attachment plates 30 are configured to removably attach oneof the diagonal braces 32 to the structural base 12 via mechanicalfasteners. As shown, one attachment plate 30 can be coupled to thestringer board 22 and the other attachment plates 30 can be coupled tothe top deckboard 20, though in other configurations of the base, theattachment plates 30 may mount to other portions of the base. Thediagonal attachment plate 30 can remain coupled to the base 12 in eitherthe upright or collapsed positions of the corner post assembly 14, butcan also be disconnected from the structural base 12 to remove thecorner post assembly from the base 12 entirely, or when collapsing thecorner post assembly 14 as described in further detail below.

As illustrated herein, the diagonal attachment plate 30 includes flatbody 104 having an inverted T-shape with one upper hole 106 and twolower holes 108. The upper hole 106 is aligned with a corresponding hole100 in the diagonal brace 32, and the pin 102 is inserted through thealigned holes 100, 106 to attach the diagonal brace 32 to the attachmentplate 30. The two lower holes 108 are used in attaching the attachmentplate 30 to the structural base 12, and can receive suitable mechanicalfasteners (not shown) such as screws, but may also receive other typesof mechanical fasteners such as nails, pins, bolts, rivets, ties, or thelike.

FIG. 11 is a perspective view of the corner post assembly 14 is in anupright and extended position. In the upright and extended position, thecorner post assembly 14 can be fully attached to the structural base 12(not shown), i.e. the post mount 28 and attachment plates 30 can both beattached to the structural base 12, and the telescoping post 26 is fullyextended, i.e. the post insert 36 is fully extended from the mainupright 34.

FIG. 12 is a perspective view of the corner post assembly 14 in anupright and retracted position. In the upright and retracted position,the corner post assembly 14 can be fully attached to the structural base12 (not shown), i.e. the post mount 28 and attachment plates 30 can bothbe attached to the structural base 12, and the telescoping post 26 isfully retracted, i.e. the post insert 36 is fully retracted into themain upright 34, with the top plate 68 abutting the upper end 40 of themain upright 34.

It is noted that the corner post assembly 14 may have other intermediatepositions, not illustrated herein, in between the fully extended andfully retracted positions shown in FIGS. 11 and 12. The corner postassembly 14 of the illustrated embodiment may, for example, extend from33″ to 50.5″ with 2″ increments as defined by the spacing between holes48. These dimensions may be particularly appropriate when the structuralbase 12 uses 2×4 lumber for the deckboards 20 and stringer boards 22.Further, instead of being discretely adjustable as determined by thespacing of the holes 48, the length of the corner post assembly 14 canbe infinitely adjustable between the fully extended and fully retractedpositions shown in FIGS. 11 and 12.

FIG. 13 is a perspective view of the corner post assembly 14 in acollapsed position. In the collapsed position, the corner post assembly14 can be collapsed to lie substantially horizontally, with thetelescoping post 26 extending laterally from the post mount 28 ratherthan longitudinally. When collapsed, the corner post assembly 14 canremain partially attached to the structural base 12. For example, FIGS.7-9 show stacked crates 10 in which the corner post assemblies 14 arecollapsed, and remain attached to the structural base 12 via the postmounts 28 though the braces 32 are separated from the attachment plates30, which remain on the structural base 12. Alternatively, the cornerpost assembly 14 can be fully removed from the structural base 12 whencollapsed, as shown for example in FIG. 13; in this case, the attachmentplates 30 can be removed from the structural base 12 and can remaincoupled with the diagonal braces 32. It is noted that the diagonalbraces 32 do not extend past the telescoping post 26 in the collapsedposition, which can help protect the diagonal braces 32 from damage.Also in the collapsed position, the telescoping post 26 can be extended,retracted, or in some intermediate position in between.

FIGS. 14-16 are close-up views showing the movement of the corner postassembly 14 from the upright position to the collapsed position.Initially, when in the upright position, the main upright 34 is receivedwith the lower end 42 engaging the upper end 84 of the post receiver 76,and the slotted tab 44 which receives the connecting bolt 90, abuttingthe top of the mounting plate 72. The telescoping post 26 is lockedsecurely in place when the locator tabs 86 extend into the lower end 42of the main upright 34 and the diagonal braces 32 are connected to thestructural base 12 (see, for example, FIG. 1).

To collapse the corner post assembly 14, the diagonal braces 32 aredisconnected, either by disconnecting them from the attachment plates30, which may remain on the structural base 12, or by disconnecting theattachment plates 30 from the structural base 12. Then, the main upright34 is moved or pulled upwardly away from the post receiver 76, as shownin FIG. 15. As the main upright 34 moves, the bolt 90 which fastens themain upright 34 to the post receiver 76 slides within the aligned slots46 on the tabs 44, which limits the distance the main upright 34 cantravel away from the post receiver 76 and ensures that the main upright34 is not fully separated from the post receiver 76. The bolt 90 canoptionally be loosened before moving the main upright 34 to permit themain upright 34 to slide a little easier. If a second bolt is in placeof a heavy payload, the second bolt can be removed before collapsing thecorner post assembly 14.

As shown in FIG. 15, the lower end 42 of the main upright 34 eventuallyclears the locator tabs 86 on the post receiver 76. The slot 46 can beconfigured such that the bolt 90 reaches the bottom end of the slot 46when the lower end 42 is clear of the locator tabs 86. Once main upright34 is free of the locator tabs 86, the main upright 34 (and thus theentire telescoping post 26) can be rotated about the bolt 90 to lie in agenerally lateral or horizontal orientation, as shown in FIG. 16.

The crate 10 can be initially assembled and collapsed in accordance withthe following methods. The sequence of steps discussed is forillustrative purposes only and is not meant to limit the method in anyway as it is understood that the steps may proceed in a differentlogical order, additional or intervening steps may be included, ordescribed steps may be divided into multiple steps, without detractingfrom the invention.

To initially assemble the crate 10, holes for the post mount 28 can bepre-drilled into each corner of the structural base 12. The corner postassemblies 14 are connected to each corner of the structural base 12using the carriage bolts 80. Before or after connection to the base 12,the height of the corner post assemblies 14 can optionally be adjusted.The diagonal braces 32 are then attached to the structural base 12 usingthe attachment plates 30 and screws that are drilled directly into thesides of the structural base 12. The assembled crate 10 is shown inFIGS. 1-3.

When assembled, the crates 10 are stackable by placing the open lowerend 85 of the post receivers 76 of one crate 10 on the locator pins 70of the corner post assemblies 14 of another crate 10, as shown in FIGS.4-6. Also when assembled, the corners posts 14 of the crate 10 arecollapsible when still attached to the structural base 12, as shown inFIGS. 7-9. Collapsing the corner post assemblies 14 allows them to layessentially flat, and provides the ability to stack multiple collapsedcrates 10 on top of one another. In addition to locking the telescopingpost 26 in place when upright, the locator tabs 86 are adapted to nestinto the post mount 28 of another corner post assembly 14 for securelystacking the collapsed crates 10. The locator tabs 86 can guide an uppercrate 10 in the stack into proper alignment with a lower crate 10 andsecurely nest within the open lower end 85 of the post receiver 76 onthe lower crate 10.

To collapse an assembled crate 10, the pins 102 attaching the diagonalbraces 32 to the attachment plates 30 are removed, and the braces 32 arefolded toward the telescoping posts 26. Alternatively, the attachmentplates 30 can be initially removed from the base 12, leaving themattached to the braces 32 as they are folded closed. The corner postassembly 14 is then collapsed according to the steps described abovewith reference to FIGS. 14-16.

In an alternative embodiment, instead of having rigid bodies 96, thediagonal braces 32 can comprise flexible straps or cables which allowthe corner post assemblies 14 to be collapsed without disconnecting thebraces 32. When upright, the cables resist racking in tension as well asact as a support cable when the crate is carrying a payload and stackedon top of another crate.

FIG. 17 shows a collapsible, stackable, and returnable crate 110according to a second embodiment of the invention. There are threeprimary component groups of the crate 110, including a structural base112, collapsible corner post assemblies 114, and various mechanicalfasteners, described in more detail below. For purposes of descriptionrelated to the figures, the terms “upper,” “lower,” “vertical,”“horizontal,” and derivatives thereof shall relate to an orientation ofthe crate 110 as shown in FIG. 17, with a lower side of the crate facingand resting on a surface (not shown). However, it is to be understoodthat the invention may assume various alternative orientations, exceptwhere expressly specified to the contrary.

The structural base 112 defines a support surface for a payload. Thestructural base 112 can be preferably fabricated from wood, while thecorner post assemblies 114 can be preferably fabricated from metal, suchas steel. This combination of materials offers a reduced-cost,collapsible crate that is robust enough to support large payloads, andcan further be stacked when assembled with at least one other crate 110as shown in FIG. 18 or stacked when collapsed with at least one othercrate 110 as shown in FIG. 19.

The structural base 112 may be customized based on the payload. Thestructural base 112 of the illustrated embodiment is customized for amotorcycle, and includes a plurality of slats that are mechanicallyfastened to each other to create the structural base 112. The slatsinclude a plurality of bottom deckboards 118 and a plurality of topdeckboards 120 that are mechanically fastened to a plurality of stringerboards 122 running between the deckboards 118, 120. Blocks 124 can alsobe provided between and mechanically fastened to the deckboards 118, 120and stringer boards 122. Mechanical fasteners such as nails, screws,pins, bolts, rivets, ties, or the like can be used for the mechanicalattachments of the base 112. Furthermore, other joining methods ofassembling the base 112 can also be used.

As with the first embodiment, other embodiments of the structural base112 are possible, including different configurations of the slats thanthat shown herein. While a customized base 112 for shipping a motorcycleis shown herein, the base on which the corners posts 114 are mounted canbe any type of base. For example, in one embodiment, the structural base112 can be a pallet. Furthermore, the corner post assemblies 114 areadapted to be transferred between different types of bases, as describedin further detail below. Also, while it is preferred that the structuralbase 112 be manufactured from a low-cost material such as wood, in otherembodiments of the crate 110, the structural base 112 can bemanufactured using a variety of materials including wood, plastic,composite, metal, fiberglass, wood-plastic composite, or somecombination of these materials. In some applications of the crate 110,it is preferred that the structural base 112 be constructed of amaterial that is lower cost than the material used for the corner postassemblies 114.

FIG. 20 is an exploded view of a corner portion of the crate 110 of FIG.17, and shows one of the corner post assemblies 114 exploded from acorner of the structural base 112. The collapsible corner postassemblies 114 are upright supports configured to provide lateralprotection to the payload, and are adapted to allow multiple crates tobe stacked when assembled or when collapsed as shown in FIGS. 18-19. Thecorner post assemblies 114 can include a post 126 and a post mount 128configured to couple the post 126 to the structural base 112.

The various components of the corner post assembly 114 can be attachedusing mechanical fasteners; alternatively, some of the variouscomponents can be welded, or otherwise attached. While the corner postassemblies 114 can be preferably fabricated from metal, and moreparticularly from steel, in other embodiments, the corner postassemblies 114 can be manufactured using a variety of materialsincluding metal, plastic, composite, wood, fiberglass, wood-plasticcomposite, or some combination of these materials. In some applicationsof the crate 110, it is preferred that the corner post assemblies 114 beconstructed of a material that is more robust than the material used forthe structural base 112, so that the corner post assemblies 114 canwithstand the repeating stacking and collapsing required of thecollapsible, stackable, and returnable crate 110.

In the illustrated embodiment, the post 126 is a single post having afixed length; in other embodiments of the crate 110, the post 126 can bea telescoping post having an adjustable length, such as shown for thecorner post assembly 14 of the first embodiment.

The post 126 includes an elongated tubular body 138 defining an at leastpartially hollow interior and having an open upper end 140 and an openlower end 142 which couples with the post mount 128. Slots 144, only oneof which is visible in FIG. 20, are formed near the lower end 142 of thetubular body 138 in opposing sides of the post 126, and maybe angled inorder to guide the post 126 between an upright position and a collapsedposition while also clearing the post mount 128. In the embodiment shownherein, the slots 144 have a dogleg shape, with a generallyvertically-extending upper slot portion 146 and a lower slot portion 148which extends at an angle to the upper slot portion 146 but is otherwisecontinuous with the upper slot portion 146.

FIG. 21 is a close-up view of the top the corner post assembly 114. Theupper end 140 includes at least one toothed upper edge 150. The toothedupper edge 150 is adapted to grip the bottom of the base 112 of anothercrate 110 for securely stacking the crates 110 (see, for example, FIG.18). As illustrated, the post 126 is rectilinear in shape, and includestwo toothed edges 150 on opposing sides of the upper end 140, and twountoothed edges 152 joining the toothed edges 150 Alternativeconfigurations of the upper end 140 are possible as long as the crates110 can be securely stacked, such as, but not limited to the entireupper edge of the post 126 having teeth, or a non-toothed configuration,such as the locator pin 70 shown in the first embodiment.

FIG. 22 is a close-up view of an interface between the stacked crates110 shown in FIG. 18, in particular the interface between one cornerpost assembly 114 of the lower crate 110 and the base 112 of the uppercrate 110. The toothed edges 150 of the corner post assemblies 114 ofthe lower crate 110 grip the base 112 of the upper crate 110 for securestacking of the crates 110. In one embodiment where the post 126 ismetal, such as steel, and the base 112 is wood, the toothed edges 150 ofthe lower post 126 can dig into the wood of the base 112.

Referring back to FIG. 20, the post mount 128 includes a corner bracket170 having a vertical mounting plate 172 and a horizontal mounting plate174 coupled with a post receiver 176 configured to receive the post 126.The mounting plates 172, 174 are configured to mount to the structuralbase 112, thereby mounting the post 126 to the structural base 112.Specifically, the vertical mounting plate 172 is coupled to one of thestringer boards 122 and one of the adjacent blocks 124, and thehorizontal mounting plate 174 is mounted to one of the top deckboards120, though in other configurations of the base 112, the plates 172, 174may mount to other portions of the base 112.

Each plate 172, 174 includes at least one hole 178 configured to receivea mechanical fastener, illustrated herein as a carriage bolt 180, usedto secure the plates 172, 174 to the structural base 112. Othermechanical fasteners are possible, as long as the mechanical fastenercan temporarily join the mounting plates 172, 174 to the base 112 toallow the post mount 128 to be removed from the structural base 112 asneeded. As illustrated, each plate 172, 174 includes two holes 178 thatare spaced and offset from each other. Offsetting the holes 178distributes the forces from the payload over a greater area within thebase 112. In general, the holes 178 can be aligned vertically, alignedhorizontally, and/or offset depending on the application andconstraints. Also, in the illustrated embodiment, two holes 178 areprovided in each plate 172, 174, though the number can vary in otherembodiments of the corner post assembly 114.

The post mount 128 can be configured as a universal mount, such that thecorner post assemblies 114 can be attached to any base, not just thestructural base 112 illustrated herein. The corner bracket 170 can besized to accommodate attaching the corner post assembly 114 to a base112 having boards or slats in a range of sizes. The mounting plates 172,174 and post receiver 176 can be fabricated from one flat plate that isstamped to define the corners of the post receiver 176 and the cornerbetween the post receiver 176 and the horizontal mounting plate 174.Alternatively, the plates 172, 174 and post receiver 176 can befabricated separately and welded or otherwise attached to form the postmount 128.

The post receiver 176 includes a U-shaped body defining an at leastpartially hollow interior and having an open upper end 184 whichreceives with the lower end 142 of the post 126, and an open lower end186 configured to meet the base 112, alongside the horizontal mountingplate 174. The U-shaped body is further open at a side that extendsbetween the upper and lower ends 184, 186,

At least one pair of holes 188 is formed along the same opposing sidesof the post receiver 176 as the slots 144. The holes 188 are used forthe connection between the post 126 and post mount 128. In theillustrated embodiment, the bodies of the post 126 and post receiver 176can be rectilinear in shape, and the body of the post 126 can nestwithin the post receiver 176. Also, while the bodies are shown as havinga rectilinear cross-section, other cross-sectional shapes are possible.

The tubular body 138 can be slidingly received in the post receiver 176to couple the post 126 with the post mount 128 and also selectivelyallow the post 126 to collapse, as described in further detail below. Tofix the post 126 on the post receiver 176, a mechanical fastener such asa bolt 190 and a nut 192 which can be threaded onto the bolt 190 can beused; optionally, a washer 194 can also be provided. In the presentembodiment, the bolt 190 is received by the holes 188 in the postreceiver 176 and the slots 144 in the post 126. The bolt 190 and slots144 form a pin-in-slot joint between the telescoping post 126 and thepost mount 128, which has two degrees of freedom such that the slots 144can slide relative to and pivot about the bolt 190, and therefore thepost 26 can slide and pivot relative to the post mount 128. Other jointspermitting translational and rotating movement between the post 126 andpost mount 128 can also be used. Other mechanical fasteners arepossible, as long as the mechanical fastener can join the post 126 andpost receiver 176 in a manner that allows the post 126 to collapse.

FIGS. 17-18 show the crate 110 with the corner post assemblies 114 in anupright position. In the upright position, the corner post assemblies114 can be fully extended from structural base 112, i.e. the posts 126can extend vertically upwardly from the corners of the structural base112. FIG. 19 shows the crate 110 with the corner post assemblies 114 ina collapsed position. In the collapsed position, the corner postassemblies 114 can be collapsed to lie substantially horizontally, withthe posts 126 extending laterally from the post mounts 128 rather thanlongitudinally. When collapsed, the corner post assemblies 114 canremain attached to the structural base 112. FIG. 19 shows stacked crates110 in which the corner post assemblies 114 are collapsed, and remainattached to the structural base 112 via the post mounts 128.

FIGS. 23-24 are close-up views showing the movement of the corner postassembly 114 from the upright position to the collapsed position.Initially, when in the upright position, the post 126 is received withthe lower end 142 within the post receiver 176 and engaging the base112, and the slots 144 receiving the connecting bolt 190. When the post126 is upright and the bolt 190 is at the top of the slots 144, the backof the post receiver 176 locks the post 126 vertically.

To collapse the corner post assembly 114, the post 126 is moved orpulled upwardly away from the post receiver 176. As the post 126 moves,the bolt 190 slides within the aligned slots 144 on the lower end 142 ofthe post 126, which limits the distance the post 126 can travel awayfrom the post receiver 176 and ensures that the post 126 is not fullyseparated from the post receiver 176. The bolt 190 can optionally beloosened before moving the post 126 to permit the post 126 to slide alittle easier. As the post 126 is lifted upwardly, the bolt 190 passingthrough the angled slots 144 forces the post 126 forward, spacing thelower end 142 of the post 126 away from the back of the post receiver176 and eventually allowing the post 126 to clear the back of the postreceiver as it is rotated about the bolt 190 to lie in a generallylateral or horizontal orientation, as shown in FIG. 24.

The crate 110 can be initially assembled and collapsed in accordancewith the following methods. The sequence of steps discussed is forillustrative purposes only and is not meant to limit the method in anyway as it is understood that the steps may proceed in a differentlogical order, additional or intervening steps may be included, ordescribed steps may be divided into multiple steps, without detractingfrom the invention.

To initially assemble the crate 110, holes for the post mount 128 can bepre-drilled into each corner of the structural base 112. The corner postassemblies 114 are connected to each corner of the structural base 112using the carriage bolts 180. The assembled crate 110 is shown in FIG.17.

When the crates 110 are assembled with the corner post assemblies 114attached to the base 112, the crates 110 are stackable by placing thebase 112 of one crate 110 on the upper ends 140 of the corner postassemblies 114 of another crate 110, as shown in FIG. 18. Also whenassembled, the corners posts 114 of the crate 110 are collapsible whenstill attached to the structural base 112, as shown in FIGS. 19 and 24.Collapsing the corner post assemblies 114 allows them to lay essentiallyflat, and provides the ability to stack multiple collapsed crates 110 ontop of one another. To collapse an assembled crate 110, the post 126 isfolded toward the base 112 according to the steps described above withreference to FIGS. 23-24.

FIGS. 25-27 show a corner post assembly 214 for a crate according to athird embodiment of the invention. A crate comprising the corner postassembly 214 can include the same three primary component groups,including a structural base, multiple corner post assemblies 214, andvarious mechanical fasteners, as described for any of the embodiments ofcrates discussed herein. It is understood that the corner post assembly214 can, for example, be used for the crate 10 or crate 110 of the firstor second embodiments in place of the corner post assemblies 14, 114discussed for those embodiments. Furthermore, the corner post assembly214 can be adapted to be transferred between different types of basesfor different types of crates.

The corner post assembly 214 is an upright support configured to providelateral protection to a payload, and is further adapted to allowmultiple crates to be stacked when assembled or when collapsed, as shownin FIGS. 25 and 26-27, respectively. The corner post assembly 214 caninclude a post 226 and a post mount 228 configured to couple the post228 to the structural base of a crate. In FIGS. 25-27, break lines areused to shorten the post 226 in order to allow an enlarged view of thecorner post assembly 214 to be shown.

The various components of the corner post assembly 214 can be attachedusing mechanical fasteners; alternatively, some of the variouscomponents can be welded, or otherwise attached. While the corner postassembly 214 can be preferably fabricated from metal, and moreparticularly from steel, in other embodiments, the corner post assembly214 can be manufactured using a variety of materials including metal,plastic, composite, wood, fiberglass, wood-plastic composite, or somecombination of these materials. In some applications, it is preferredthat the corner post assembly 214 be constructed of a material that ismore robust than the material used for the structural base, so that thecorner post assembly 214 can withstand the repeating stacking andcollapsing required of a collapsible, stackable, and returnable crate.

The post 226 includes at least one elongated tubular body 238 definingan at least partially hollow interior and having an upper end 240 and alower end 242 which couples with the post mount 228. The upper end 240may have a locator pin as described for the first embodiment, a toothedupper edge as described for the second embodiment, or neither, as shownherein. The post 226 can be a single post having a fixed length;alternatively, the post 226 can be a telescoping post having anadjustable length, such as shown for the corner post assembly 14 of thefirst embodiment.

The post mount 228 includes a corner bracket 270 configured to beattached to the corner of a structural base, thereby mounting the post226 to the structural base. The bracket 270 can have a first U-shapedreceiver 272 and a second U-shaped receiver 274 joined in an L-shape andcoupled with a post receiver 276 configured to receive the post 226. Thebracket 270 can be attached to a crate base by one or more mechanicalfasteners or another joining method.

The U-shaped receivers 272, 274 are configured to hold stringer boardsthat create a frame for the structural base. This allows for astructural base without bottom deck boards, which makes the use of apallet jack much easier. The U-shaped receivers 272, 274 can optionallyfurther comprise a tooth system to attach the corner post assembly 214to the base. As shown in the illustrated embodiment, the U-shapedreceivers 272, 274 have triangular or tooth-shaped cutouts 278 that arepushed in so when the stringer boards for the base are forced into theU-shaped receivers 272, 274, the or tooth-shaped cutouts 278 bite intothe stringer boards and lock them into place, eliminating the need foradditional mechanical fasteners.

The post receiver 276 includes a U-shaped body defining an at leastpartially hollow interior and has an open side 282 and an open upper end284 which receives with the lower end 242 of the post 226. In theillustrated embodiment, the bodies of the post 226 and post receiver 276can be rectilinear in shape, and the body of the post 226 can nestwithin the post receiver 276. Also, while the bodies are shown as havinga rectilinear cross-section, other cross-sectional shapes are possible.

The post 226 can be connected with the post mount 228 by a pin-in-slotjoint, whereby the tubular body 238 can be slidingly received in thepost receiver 276 in an upright or assembled position as shown in FIG.25, and also selectively allow the post 226 to collapse, as described infurther detail below, as shown in FIGS. 26-27. Other joints permittingtranslational and rotating movement between the post 226 and post mount228 can also be used.

First slots 286 are formed in opposing sides of the post receiver 276. Asecond slot 288 is formed in the first U-shaped receiver 272, and is atleast partially coextensive with the first slots 288. The slots 286, 288can be elongated generally in the lengthwise or vertical direction ofthe post 226.

To fix the post 226 on the post receiver 276, a mechanical fastener orpin 290, such as a bolt and a nut which can be threaded onto the bolt,can be used, and extends through the post 226 and through the slots 286,288. The pin 190 and slots 286, 288 form the pin-in-slot joint, whichhas two degrees of freedom such that the post 226 can slide and pivotrelative to the post mount 228. The first slots 286 are closed at theupper and lower ends thereof to prevent the post 226 from being entirelyseparated from the post receiver 276 as the post 226 is moved relativeto the post mount 228, while the second slot 288 is open at an upper endthereof, which allows the pin 290 to drop below the upper edge of thebracket 270.

The post mount 228 further comprises a post pocket 292 configured tonest with another corner post assembly 214 on another crate for securingstacking the crates. As illustrated, the post pocket 292 is flaredoutwardly and has a wide base 294. For example, the base 294 can bewider than the upper portion of the pocket 292 and the post receiver276. The flared shape of the pocket 292 can help guide an upper crate inthe stack into proper alignment on top of a lower crate. Crates arestackable by placing the pockets 292 of one crate on the upper ends 240of the posts 226 of another crate. The wide base 294 of the pockets 292also eases stacking crates when the corner post assemblies 214 arecollapsed. When collapsed, crates are stackable by resting the wide base294 of the pockets 292 of one crate on top of the post mounts 228 ofanother crate. Alternative configurations of the post pocket 292 arepossible, as long as the crates can be stacked when assembled orcollapsed.

FIG. 25 shows the corner post assembly 214 in an upright position. Inthe upright position, the corner post assembly 214 can be fully extendedfrom structural base, i.e. the posts 226 can extend vertically upwardlyfrom the corner of the structural base. The post 226 is received withthe lower end 242 within the post receiver 276, and the pin 290 is at orcloser to the bottom of the aligned slots 286, 288. The back of the postreceiver 276 can lock the post 226 vertically.

FIGS. 26-27 show the corner post assembly 214 in a collapsed position.In the collapsed position, the corner post assembly 214 can be collapsedto lie substantially horizontally, with the post 226 extending laterallyfrom the post mount 228 rather than longitudinally. When collapsed, thecorner post assembly 214 can remain attached to the structural base.Further, crates can be stacked when the corner post assemblies 214 arecollapsed, which can remain attached to the structural base via the postmounts 228.

To collapse the corner post assembly 214, the post 226 is moved orpulled upwardly away from the post receiver 276. As the post 226 moves,the pin 290 slides within the aligned slots 286, 288, which limit thedistance the post 226 can travel away from the post receiver 276 andensures that the post 226 is not fully separated from the post receiver276. The pin 290 can optionally be loosened before moving the post 226to permit the post 226 to slide a little easier. As the post 226 islifted upwardly, the pin 290 eventually clears the slot 288 in the firstU-shaped receiver 272, and the post 226 is rotated to lie in a generallylateral or horizontal orientation, as shown in FIG. 26.

As shown in FIGS. 26-27, when the corner post assembly 214 is collapsed,the upper edge 284 of the post receiver 276 can be substantially flushwhich the side of the tubular body 238 to enable crates to be stacked.Alternatively, the upper edge 284 of the post receiver 276 can be raisedrelative to the side of the tubular body 238 for nesting further intothe post pocket 292 when collapsed crates are stacked.

It is noted that any of the crate embodiments disclosed herein can beprovided as a complete crated solution, including a structural base,collapsible corner post assemblies, and various mechanical fasteners.Alternatively, the corner post assemblies 14, 114, 214 can be packagedas a universal kit which is attachable to any base or pallet. Stillfurther, a rental system is contemplated in which a whole crate or justcorner post assemblies are rented on a per use basis.

It is further noted that while various mechanical fasteners arediscussed herein for joining particular components of the crateembodiments disclosed herein, it is understood that alternativemechanical fasteners such as screws, pins, bolts, rivets, ties, nails,or the like can be used for the mechanical attachments described, unlessotherwise noted. Furthermore, other methods of joining the components ofthe crate embodiments disclosed herein can be used, including, but notlimited to, crimping, welding, soldering, brazing, taping, gluing,cementing, or the use of other adhesives, unless otherwise noted.

It is further noted that while the crate embodiments disclosed hereinmay be described as being returnable, any of the crate embodimentsdisclosed herein can also be configured for one-way use. A returnablecrate can, for example, be made from more heavy duty components than aone-way crate, such as having thicker steel for the post mounts, largertube sizes for the posts, and/or bolting the corner post assemblies tothe base with a nut and washer instead of simply screwing the cornerpost assemblies to the base with deck screws or lag screws.

The embodiments of the invention disclosed herein provide for acollapsible and stackable crate that improves over prior crate systems.The crate provides a strong, stackable system that can be folded flatfor storage or shipping. The corner post assemblies provide theflexibility to be used with any size base or pallet configuration. Thecorner post assemblies are collapsible, which allows them to lay flat &provides the ability of stacking systems on top of one another. In someembodiments of the invention, the corner post assemblies further have anadjustable length to accommodate for differently-sized payloads and/orstacking heights. The crate is durable and at least some embodiments ofthe invention can offer a conveniently returnable system that can bereused many times. The crate can be preferably constructed from bothwood and steel, which offers both affordability and strength.

While the invention has been specifically described in connection withcertain specific embodiments thereof, it is to be understood that thisis by way of illustration and not of limitation. Reasonable variationand modification are possible with the scope of the foregoing disclosureand drawings without departing from the spirit of the invention which,is defined in the appended claims. Hence, specific dimensions and otherphysical characteristics relating to the embodiments disclosed hereinare not to be considered as limiting, unless the claims expressly stateotherwise.

What is claimed is:
 1. A collapsible crate, comprising: a structuralbase for supporting a payload and having at least one corner; and acollapsible corner post assembly coupled with the structural base, andcomprising: a post mount coupled to the at least one corner; and anelongated post coupled to the post mount; and wherein the elongated postis moveable relative to the post mount between: an upright position inwhich the post extends upwardly from the post mount, substantiallyvertically relative to the structural base; and a collapsed position inwhich the post extends laterally from the post mount, substantiallyhorizontally relative to the structural base.
 2. The collapsible crateof claim 1, wherein the corner post assembly further comprises apin-in-slot joint between the elongated post and the post mount, wherebythe elongated post can slide and pivot relative to the post mount formovement between the upright position and the collapsed position.
 3. Thecollapsible crate of claim 2, wherein the pin-in-slot joint comprises aslot provided one of the elongated post and the post mount, and a pinfixed to the other of the elongated post and the post mount.
 4. Thecollapsible crate of claim 3, wherein the slot is angled.
 5. Thecollapsible crate of claim 3, wherein the slot comprises a dogleg shape.6. The collapsible crate of claim 1, wherein the elongated postcomprises a telescoping post moveable between a retracted position andan extended position, wherein the telescoping post is longer in theextended position than in the retracted position.
 7. The collapsiblecrate of claim 6, wherein the telescoping post comprises: a main uprightdefining an at least partially hollow interior and having an open upperend and a lower end which couples with the post mount; and a post insertat least partially received in the open upper end and slidable withinthe main upright.
 8. The collapsible crate of claim 7, wherein aplurality of holes are formed in each of the main upright and postinsert, and the corner post assembly further comprises a mechanicalfastener adapted to be inserted through a set of aligned holes in eachof the main upright and post insert to releasably set the telescopingpost at a desired length.
 9. The collapsible crate of claim 6, whereinthe corner post assembly further comprises: an attachment plate mountedto the structural base in spaced relation to the post mount; and adiagonal brace extending diagonally between the telescoping post and theattachment plate.
 10. The collapsible crate of claim 6, wherein thetelescoping post comprises a first end coupled to the post mount and asecond end comprising a nesting feature adapted to nest with anothercrate, allowing multiple assembled crates to be stacked.
 11. Thecollapsible crate of claim 1, wherein the elongated post comprises anesting feature adapted to nest with another crate, allowing multipleassembled crates to be stacked.
 12. The collapsible crate of claim 1,wherein the elongated post comprises a locator pin on an upper endthereof that is adapted to nest into a post mount of another collapsiblecrate for securing stacking the crates.
 13. The collapsible crate ofclaim 1, wherein the elongated post comprises at least one toothed edgeon an upper end thereof that is adapted to dig into a base of anothercollapsible crate for securing stacking the crates.
 14. The collapsiblecrate of claim 1, wherein the post mount comprises a vertical mountingplate coupled to one side of the at least one corner, a horizontalmounting plate coupled to another side of the at least one corner, and apost receiver coupled with the elongated post.
 15. The collapsible crateof claim 14, wherein the post receiver comprises an elongated tubularbody extending upwardly beyond the horizontal mounting plate and havingan upper end which abuts the elongated post when the elongated post isin the upright position.
 16. The collapsible crate of claim 14, whereinpost receiver comprises a U-shaped body defining an at least partiallyhollow interior which receives a lower end of the elongated post andcomprising an open upper end and an open side, wherein the elongatedpost moves through the open upper end and the open side when movingbetween the upright and collapsed positions.
 17. The collapsible crateof claim 1, wherein the post mount comprises at least one locator tab,wherein, when the elongated post is in the collapsed position, the atleast one locator tab extends beyond the elongated post and is adaptedto nest into a post mount of another crate for securing stacking thecrates.
 18. The collapsible crate of claim 17, wherein, when theelongated post is in the upright position, the at least one locator tabextends into the elongated post.
 19. The collapsible crate of claim 1,wherein the structural base comprises a plurality of wooden boardsmechanically fastened to each other and the collapsible corner postassembly is fabricated from metal.
 20. A corner post assembly for acrate comprising a structural base, the corner post assembly comprising:a post mount configured to couple to a corner of the structural base;and an elongated post coupled to the post mount; and wherein theelongated post is moveable relative to the post mount between: anupright position in which the post extends upwardly from the post mount;and a collapsed position in which the post extends laterally from thepost mount.